Timing Belt

Removal & Installation

2.4L Engine

Valve Timing Belt

To Remove:

1. Remove the engine mount bracket.
2. Remove the drive belt (power steering oil pump and A/C compressor).
3. Remove the drive belt (generator).
4. Remove the water pump pulley.
5. Remove the crankshaft pulley.
6. Remove the timing belt upper cover assembly.
7. Remove the timing belt lower cover assembly.

   CAUTION
   The crankshaft should ONLY ever be turned in the forward direction.

8. When removing the timing belt, do the following:
   • Step 1: Rotate the crankshaft in the forward direction (toward the right) to line up the camshaft sprocket timing marks.

     CAUTION
     If the timing belt is to be reused, mark the flat side with an arrow to show the clockwise direction. Use chalk to mark the timing belt.

   • Step 2: Loosen the tension pulley fixing bolt.
   • Step 3: Move the tension pulley to the water pump side then remove the timing belt.
9. Remove the tensioner pulley.
10. Remove the auto tensioner.

To Install:

CAUTION
Never compress the pushrod too quickly because damage may occur.

1. To install the auto-tensioner, do the following:

   Auto-tensioner

   • Step 1: Apply 22-44 lb (98-196 N) of force to the pushrod of the auto-tensioner by pressing it against a metal object (like the engine block) then measure the movement of the pushrod. Standard value: Within 0.04 in (1 mm).
     1. X = Length when auto-tensioner is not pressed
     2. Y = Length when auto-tensioner is pressed
     3. X – Y = Movement
   • Step 2: If the measurement is outside the standard value, replace the auto-tensioner.

     Auto-tensioner pin hole alignment

   • Step 3: Use a vise to carefully compress the auto-tensioner pushrod until pin hole X of the pushrod and pin hole Y of the tensioner cylinder are lined up.
   • Step 4: Once the holes are aligned, insert the set pin.

     NOTE: If you are replacing the auto-tensioner with a new part, the pin will be found in the auto-tensioner.

   • Step 5: Install the auto-tensioner onto the engine.
2. Install the tensioner pulley.
3. To install the timing belt, do the following:
   • Step 1: Line up the timing marks on the camshaft sprocket, crankshaft sprocket, and oil pump sprocket.
   • Step 2: After lining up the timing mark on the oil pump sprocket, remove the cylinder block plug and insert a 0.3 in (8 mm) Phillips head screwdriver. Check to be sure that the screwdriver goes in at least 2.4 in (60 mm). If the screwdriver will not go in more than 0.8-1.0 in (20-25mm) before it hits the counterbalance shaft, turn the sprocket once, realign the timing marks and make sure the screwdriver goes in at least 2.4 in (60 mm). The screwdriver should not be removed until the timing belt is installed.

     CAUTION
     If the timing belt will be reused, install it so the arrow made during removal is pointing in the clockwise direction.

   • Step 3: Install the belt onto the crankshaft sprocket, oil pump sprocket, and camshaft sprocket in that order, to ensure the belt tension has no slack.
   • Step 4: Set the tension pulley so that the pin holes are at the bottom, press the tension pulley gently against the timing belt, then temporarily tighten the fixing bolt.
   • Step 5: Adjust the timing belt tension.

   CAUTION
   Do not use a wrench or other tool to turn the adjusting screw (special tool #MD998738) because the auto-tensioner set pin might break. Only turn the adjusting screw (special tool #MD998738) by hand.

4. When adjusting the timing belt tension, do the following:
   • Step 1: Remove the rubber plug from the rear of the timing belt cover assembly. Next, screw in an adjusting screw (special tool #MD998738) by hand until the tensioner arm is touching the auto-tensioner pushrod.
   • Step 2: After rotating the crankshaft ¼ of a turn counterclockwise, rotate it in the clockwise direction until the timing marks are lined up.

     CAUTION
     When you tighten the fixing bolt, be sure the tension pulley does not turn with the bolt.

   • Step 3: Loosen the tension pulley fixing bolt, then use the tensioner pulley socket wrench (special tool #MD998767) and a torque wrench to tighten the fixing bolt to 36 ft-lbs (48 Nm) while applying tension of 31 in-lbs (3.5 Nm) to the timing belt.
   • Step 4: Remove the set pin that had been inserted into the auto-tensioner, then remove the tensioner pulley socket wrench (special tool #MD998767).
   • Step 5: Rotate the crankshaft two revolutions clockwise so that the timing marks are lined up. After leaving it for 15 minutes, measure the amount of protrusion of the auto-tensioner. The standard value is 0.15 - 0.18 in (3.8 - 4.5 mm).
   • Step 6: If the amount of protrusion is outside of the standard value, repeat steps 1 - 5.
   • Step 7: Make sure the timing marks on each sprocket are lined up.
5. Install the timing belt lower cover assembly.
6. Install the timing belt upper cover assembly.
7. Install the crankshaft pulley.
8. Install the water pump pulley.
9. Install the generator drive belt.
10. Install the drive belt for the power steering oil pump and A/C compressor.
11. Install the engine mount bracket.
12. Check the drive belt tension.

Balancer Timing Belt

To Remove:

NOTE: Mark the rotating direction of the timing belt if reusing the belt. Always install the belt in the original direction.

1. Remove the timing belt idler pulley.
2. Remove the timing belt lower cover bracket and crankshaft position sensor.
3. Remove the crankshaft sprocket.
4. Remove the crankshaft angle sensing blade.
5. Loosen the tensioner pulley bolt and remove the belt.

To Install:

1. Align the timing marks and install the belt on the sprockets.
2. Rotate the tensioner pulley by hand to remove all looseness from the belt and tighten the bolt to 14 ft-lbs (19 Nm).
3. Turn the crankshaft clockwise two complete turns and verify the timing marks align.
4. Apply a force of 13 lbs (59 N) at the center of the belt tension side. Verify belt deflection is 0.43 inch (11 mm).
5. Install the crankshaft angle sensing blade.
6. Install the crankshaft sprocket.
7. Install the timing belt lower cover bracket and crankshaft position sensor.
8. Install the timing belt idler pulley.

3.0L Engine

To Remove:

1. Remove the drive belt (power steering oil pump).
2. To remove the crankshaft pulley, use an end yoke holder (special tool #MB990767) and a crankshaft pulley holder pin (special tool #MD998715) to remove the crankshaft pulley from the crankshaft.
3. Remove the tensioner pulley assembly (power steering oil pump).
4. Remove the timing belt front upper cover (right side).
5. Remove the timing belt front upper cover (left side).
6. Remove the timing belt front lower cover.
7. Remove the engine support bracket (right side).
8. When removing the timing belt, do the following:
   • Step 1: Turn the crankshaft clockwise to line up each timing mark and to set the #1 cylinder to compression top dead center.
   • Step 2: If the timing belt will be reused, use chalk to draw an arrow on the flat side of the belt showing the clockwise direction.
   • Step 3: Loosen the center bolt from the tensioner pulley, then remove the timing belt.
9. Remove the auto-tensioner.
10. Remove the tensioner pulley.
11. Remove the tensioner arm.

To Install:

1. Install the tensioner arm.
2. Install the tensioner pulley.
3. To install the auto-tensioner, do the following:

   Auto-tensioner

   • Step 1: Apply 22-44 lb (98-196 N) of force to the pushrod of the auto-tensioner by pressing it against a metal object (like the engine block) then measure the movement of the pushrod. Standard value: Within 0.04 in (1 mm).
     1. X = Length when auto-tensioner is not pressed
     2. Y = Length when auto-tensioner is pressed
     3. X – Y = Movement
   • Step 2: If the measurement is outside the standard value, replace the auto-tensioner.

     CAUTION
     Put the auto-tensioner perpendicular to the jaws of the vice. If there is a plug at the base of the auto-tensioner, insert a plain washer onto the end of the auto-tensioner to protect the plug.

     Auto-tensioner pin hole alignment

   • Step 3: Use a vise to carefully compress the auto-tensioner pushrod until pin hole X of the pushrod and pin hole Y of the tensioner cylinder are lined up.
   • Step 4: Once the holes are aligned, insert the set pin.

     NOTE: If you are replacing the auto-tensioner with a new part, the pin will be found in the auto-tensioner.

   • Step 5: Install the auto-tensioner onto the engine.
4. When installing the timing belt, do the following:
   • Step 1: Line up the timing marks on the camshaft sprockets with those on the rocker cover and the timing mark on the crankshaft sprocket with that on the engine block.

     CAUTION
     The camshaft sprocket (right bank) can easily turn because of the spring force applied, o be careful not to get your fingers caught.

   • Step 2: Install the timing belt using the following procedure so that there is no deflection in the timing belt between each sprocket and pulley.
     1. Crankshaft sprocket
     2. Idler pulley
     3. Camshaft sprocket (left bank)
     4. Water pump pulley
     5. Camshaft sprocket (right bank)
     6. Tensioner pulley
   • Step 3: Rotate the camshaft sprocket (right bank) counterclockwise until the tension side of the timing belt is stretched firmly. Examine the timing marks again.
   • Step 4: Use a tensioner pulley socket wrench (special tool #MD998767) to push the tensioner pulley into the timing belt, then temporarily tighten the center bolt.
   • Step 5: Use a crankshaft sprocket spacer (special tool #MD998769) to rotate the crankshaft ¼ turn counterclockwise, then rotate it again clockwise until the timing marks are lined up.

     CAUTION
     When tightening the center bolt, make sure the tensioner pulley does not turn with the bolt.

   • Step 6: Loosen the center bolt of the tensioner pulley. Use a tensioner pulley socket wrench (special tool #MD998767) and a torque wrench to apply the tension torque to the timing belt as shown. Next, tighten the center bolt to 36 ft-lbs (48 Nm). The standard value is 39 in-lbs (4.4 Nm) [Timing belt tension torque]
   • Step 7: Remove the setting pin that was inserted into the auto-tensioner.
   • Step 8: Rotate the crankshaft clockwise twice to line up the timing marks.
   • Step 9: Wait for at least five minutes, then check that the auto-tensioner pushrod extends within the standard value range. The standard value is 0.15 – 0.20 in (3.8 – 5.0 mm).
   • Step 10: If not, repeat the operation in steps 5 through 9.
   • Step 11: Check again that the timing marks of the sprockets are lined up.
5. When installing the right engine support bracket, tighten the right engine support bracket mounting bolts in the order shown.

   Right engine support bracket

6. Remove the timing belt front lower cover.
7. Remove the left timing belt front upper cover.
8. Remove the right timing belt front upper cover.
9. Remove the tensioner pulley assembly (power steering oil pump).
10. To remove the crankshaft pulley, use an end yoke holder (special tool #MB990767) and a crankshaft pulley holder pin (special tool #MD998715) to install the crankshaft pulley.